Ceramic product



Feb. 4, 1941. A G. w. REED 2,230,309

CERAMIC PRODUCT Filed .June 4, 193e j; Elf/E4.

40 'f eZf y E y a0 "'25 @e .5444 y INVENTOR Bm gordon Zdjed l ATTORNEYS.

' Patented Feb. 4, 1941 UNITED STATES PATENT OFFICE Claims.

The present invention relates to the manufacture of ceramic constructionunits.

More particularly the present invention relates to the production ofrelatively vitreous units, such as building tiles, adapted for use instructures where a high degree of impermeability is desirable. Buildingunits of this character are conventionally formed and fburned in a kiln,the desired degree of vitrication of the product 0 being dependent inlarge measure on careful control of the burning operation. The instanttiles being normally of prismatic shape, when packed into a kiln forburning, provide a relatively dense packing and, as a result, do notthoroughly ventilate during the heating operation, It is, accordingly,necessary, in order to maintain the desired uniformity and control oftemperature, that themass be heated in the kiln over a.rel atvely greatlength of time. So also this prod- 20 uct, in spite of slow and carefulcooling, is, when made in the conventional manner described above,characterized by a great per cent of breakage since the Aproduct isrelatively susceptible to destruction'under adverse heat conditions.

The present invention more particularly contemplates the production ofvitreous ceramic units of the above character by first providing a massof suitable plastic material in the form of an element comprising acentral aperture 30 having a shape corresponding to the shape of aplurality of the ultimate units, but wherein the units are joined byintegral connecting portions along opposite side edges and which may bebroken apart to provide improved mortar adhering surfaces.

Unitary elements of this character may be readily stacked in the kiln toprovide complete ventilation of the kiln packing so that heating will berendered substantially uniform throughout the mass. As a result of thisarrangement, the time of heating and cooling may, not only be sharplyreduced, but the waste or loss due t0 breakage substantially eliminated.

Prior attempts to provide a process of this type have in generalresulted in final tile units having surfaces unsuitable for assemblyinto a structure having the desired degree of impermeability. It isimportant to note that the usual mortars -0 employed to join theindividual units in the iinished structure are relatively porous andfree from any substantial degree of impermeability. Thus, unless theindividual tiles are maintained within reasonable limits, the sanitaryand moisture-retaining character of the resulting struc- (Cl. 'I2-37)ture is lessened and the real purpose of lusing such tiles is defeated.

One type of tile, 'resulting from the attempts to provide adequateventilation during burning, has been formed with sometimes jagged andirregular projecting portions located at or in the vicinity ol thesurfaces to be mortared and thus prevented proper tting and alinement ofthe units. Thesev projecting portions, moreover, have resulted in aninordinately large spacing between adjacent tiles so that an undesiredamount of permeable mortar surface is exposed.

It is, accordingly, an object of the present invention to obviate theabove discussed difficulties and to provide an element adapted to beburned while completely ventilated and which at the same time may bereadily broken apart after burning'to provide individual tiles free fromundesired surface projections and adapted to be properly alined in thenished structure and to be assembled closely with a mortar joint ofminimum extent.

A further object of the present invention is to provide a process ofmanufacturing tile as well as an intermediate tile forming unit of theabove character comprising a series of tile sections corresponding inform to the nished tile construction units, being integrally joined andbeing adapted to be readily broken apart to provide units having adesired uniform and symmetrical configuration and being free from'-irregular or projecting portions which would tend to enlarge theadjacentmortar joint.-

Another object of the present invention is to provide a process andproduct as abovel wherein the .integrally formed tile sections arearranged in generally polygonal order and joined along side edges byreadily breakable means adapted to be broken interiorly of the normalplane 0f said side surface whereby the broken surfaces are ultimatelyformed interiorly of the normal outer confines of the tile in order topermit close abutment of the units in the finished structure.

An additional object of the present invention is to provide a ceramicconstruction unit and particularly a construction unit of the highlyvitreous type having roughened, broken edges for interlocking withmortar to provide an improved mortar joint but wherein the roughened orbroken surfaces are positioned interiorly of the outer side plane of theunit whereby to permit assembly with narrow mortar joints.

It is furthermore an object of the present. invention to provide aconstruction element as above having longitudinally recessed side edges,

Fia

a portion of the interior surface of the recess comprising a broken,irregular edge adapted for improved mortar adherence, substantially allof the broken or irregular surface being located within the recess. i s

The present invention additionally contemplates tlie provision of aunitary form' of relatively plastic tile making material comprising laseries oi sections corresponding to the shape of the finished tile unitsand integrally joined together by connecting :or bridging portions,-ltho connecting portions so arranged in forr'rrl as to permitlimited, angular /movmentof lth'e1sec-- tions joined thereby undertheQinucnce v'of .the

elevated temperatures prevailing .in thetkiln;

It is, accordingly, an object of the present fine' vention to provide anelement ladapted 'j toibe" burned in the' kiln whereinv any distortingor warping tendencies are caused torac't upontlie.' relatively thinbridging-or connecting portions.v

between the respective tile unit sections so thatthe finished tile unitswill possess their predetermined, undistorted form. o

A yet further object of the present invention is to provide a processcomprising the forming or extrusion of a plastic mass of tile making"materials-into a predetermined section. burning the section whilecompletely ventilatedl-and' thenA breaking the .section apart alongpredetermined lines of integral juncture to provide ceramic tiles ofpredetermined, generally prismaticv exterior configuration freefromprojectirig broken surf faces.

Numerous other objects and advantages will l more fully appear duringthe course and progress of the following specification.

Figure 1 is a sectional view taken vertically and cent-rally through anextrusion machine consti'ucted for the purpose of carrying out theprocess of the present invention. A

Figure 2 is a detail sectional view taken on the line 2--2- in Figure 1.v

Figure `3 is a perspective view oi the extruded 'Y element or sectionformed by thernach-ine'in` Figures 1 and 2.

Figure 4 is an end view ol the extrudedelel ment shown in Figure 3 theparts being shown in relatively`separated position after-burnirig andbreaking. v .l t

Figure 5 is a perspective view of Aa finished tile embodying thefeatures of the present invention.'

Figure 6 is an end elevational viewjshowing a 1 plurality of theconstruction units of Figure 5 assembled together through the agency ofa. suitable mortar to provide a relatively impermeable' floor structure.

Referring tothe figures of the drawing, wherein the present invention isdisclosedmore'in de` tail, Figures 1 and 2 show a machineadapted toextrude a. section suitable fory burning andl the production ofconstruction elements in accordance with the present invention.

'The extrusion device, which is shown more or less diagrammatically inthe figures, isl of the auger type comprising a chamber l0 fed withsuitable, preferably relatively plastic tile making material through ahopper I2.` .The plastic material in the chamber I0 is fed progressivelyin the righthand direction. as viewed in. Figure 1, through the l.agencyof an auger or spiral' cor'iv veyor I4 mounted on a shaft Iii-and,journ`alled 'at one end in the bearing I8 supported by the plurality ofstruts 20 and at the other end in the wall 22. It will be understoodthatthe shalt i6 is driven by any suitable means inot shown).

. tions MJ.l of, t e* extruded :that these 'bridging f 'r' connectingThe plastic material advancing to the right in Figure 1, passes throughthe extrusion head or orifice 24, secured to the chamber l0 by fasteningmeans 26.

Attention is directed to the fact the extrusion head, 24 is ofgenerally'rectangular forin and supports centrally tiiermi, throughtheiagency of struts 29, av frminglmember or die 28 of similarrectangular',configuration 'so that'theplastic extri'idedr material ine-ilectl passes through a.

space defined by co-axialp'rectangular innerand ejec'truded prodout erlimits and, accordinglyuct possesses, the corig'ii-rationj diajrectangular, tubular section? JIt- ,is rnoreover`, important to 'note.that thevouterportion'ofthe @extrusion head 24 is 'provided withfzifghtfv inwardly vprojecting Aforming'rinexribers-3ll.vTwootthetorniing mem- V bers 30a-'are'mounted-.kin leach'side v'wall fthe f member' 24, being rigidlyapositioned as layweldfA ingv inappropriate grooves. The" inwardly projecting reeends of the. members 30Yare oppovsitely inclined and sharpened as at 32. v

The inner forming member or `die r28.is lprovided with similarlyarranged members illv mounted at the four corners thereof and sopositioned that theyare aligned ,in the same `plane with the`correspondingfmembers 32. yEachA ofy sharpened; free edge. portion- '36spacedfa` pre'- 'cletermined distance from1th'einc1in'ed edge ponl tion32 'ofthe-opposite for'n'inggmernber 30;

It will be obvious. from vthejabove .desririation that the section ofplastic material Iproceeding from/the extrusionv head will have:a-'cro's'sfsectional shape, as shown inv Figure 3. Particular attentionis directed tothe -fa'ct that the sections of material enclosed' by theforming.platesA or members 3 0 an d 3v4 and' theropposed;'sides'v of theinner and outer forming members j28` correspond to the cross sectionalshapeiof the finished construction elernent.

In other words, the extrudedproduct orelement comprises four portionscorresponding `in cross sectionalv` size an'd Shape tothe ynished tile,y th'e'sej elements; being l indicated '.by' the reference numeral 38fand'beinlintegrallyQ joined by borner oriconnecting, portions, @0

bridging f portions of .cmrlistric ed ,'Attentionfiislj particularl inthe embodiment shown, c river@ nie uniti-sections 'fsay andthe-aaneenisidejsurinclined` sharpened' forming `portuii'an's '32'.1and 736 I isaresult ofI the 'itlie forming members"34likewise-hasia-inclined,

oThesebridgingremous-arenidictebrthe refr'- I erenc'e aumen-142.1 ,It'wiilfbe'fnoteqfthat they -arereiativeiythirilo narrowvWiart-.re.spettito' the thicknessjor the adjacent-material.

of the extrusionhead provide,"alongitudinally extending recess' alongthe tile. sections 38 forv Y accommodating the narrow end ofthe-bridgingor connecting portion Q2. 'ly hus", r;the ln'arrc'mor Ythin end of the'bridging 'portions 42pro`vides a' breaklolf section forseparating'the`tile units,`

as will appear-hereinafter more in'detail.-

I'n accordance with the *present invention, itv is contemplated that the'extrudedv .Section emanating from v the extrusion device. be severedvcutting.means 4Q? arranged above the top nightl vof theconvfeyor Aand'adaptedfto 'be-4 actuated .i downwardly at predetermined; intervals. tosever Avfwire.. sawforany .otherl conventional device; n,

' '.-f'lhe ,centra Vdi'eforl fovrmingpzi'nember" 13,' vasclearly.sh'owlf inly Figure V2, is `provided with outt the presentinvention, it will be noted that substantially none of the projectionsformed -by the irregularity of the broken surface 64 will extend-vbeyond the outery or bounding plane of the side n wallor, irlotherwords, beyond the planes inv into lengths corresponding to the length ofthe ilnished tiles. An endless conveyor 48 engages the .extruded lengthoi; material and serves to convey it continuouslyr 4in the righthanddirecshown). 'Cooperating vwith the conveyor 46 is a ltion through theagency `of drive means (noti thev material *into elements of.predetermined length. They 4cutting; means v48' Vmaycmprise awardlyprojecting' portionsifih; on fitsj; periphery viceimprovidedfrwitn grooves-v'io'r serrations 52 )bottom or rear, faceofthe yiinsl'ied tile units.y

f Reverting'tothe showingof the extruded and severed element shown inlFigure 3, attention is directed/to the fact that each. of the tileAunit* sections 38 comprises an outer flat surface 54 each tile are-providedby theaction'ofA the out. [ting vmeans 4 8 hereinbeforedescribed.`

. exercised meanwhile'uto preventbreakage. The]v ,elements maybe. packedinto the kilnfin any dels'ired manner -'to-:providerelatively vfreeypassage ,cent tile sectionA ,3,8'.; 'The line "ofi breakage, more-vwhich constitutes the -top or outer surface of the finished tile andresides in an exposed portion in the ultimate tile structure.

The grooved, uted or serrated inner face 56 offeachr of the portionsfconstitutesitli'e opposite or lower-face of the tilev and it will beapparent'that the vg-rooves52 vprovide'for increased ymortaradherencein,reta'ini'ng the tiles in op-v erative. position.' Accordingly, lthesurfaces of the sections 38fexter'idi`ng longitudinally of fthe extrudedelement and transversely between the surfaces 54- and v56 constitutetheside walls or edges of tliejnish'ed tiles and aredesignated bythenumeral 58. 'It will vbeunderstood from the above disclosures'.lthat; .the end" surfaces 50 `of In proceeding-in accordance withl thepresent invention, the extrudedl elements are carefully dried and packedin a `suitable kiln, care being along l the*y inner isuri acescorresponding to l the of Athe' kilnJ gases through zthe mass 'ofmaterial so thatv heating and .'cooling. may proceed sub-4stantially-uniformly as to all.. portions thereof'. v, .'I'he generallypolygonal arrangement oi' the integrally, joinedti'le sections 3,8 'withthe central nue `or l aperture extending longitudinally theref betweenpermits the-kiln; to -be readily packed lin this. manner. :Aftersubjecting thekiln pack- 'ling to the required temperature'for arequired length Aof time, `'-,tflive' temperature is, lowered and ing.and separatingv the individualmtiles v.

Breakage' isreadily accomplished by subjecting upon the variouslportionsfthereofgwill break o apart, Aas clearlyshown in Figure 4.Attention `the burned vit'reous'gprcnliuctv removed for breakv.thevitreous element to` a sharp blow orjar whereis particularly 'directedto the fact that breakage' occurs substantiallyat the'thinnest 4part .ofthe bridging orl'connectingportion 42, namely, l.sub-

stantially at-ythe p'oi'ntwherz'afitjoins'the adjaoven-willoc'curinteriorlyfof the longitudinally extending side`vr`e'p'ressiorifsv formedzby the inclined interiorly'ofhthe sides ofA eachtile .sectionf,'prov'ide' a. recess, which has been, indicated generallylby the .referenced nii'ieral, 62..'.and the breakage ofthe v `tending'fa-'ces 58 is provided centrally with a longitudinally within thisrecess. As a result, the jagged, irregular or broken surface resultingfrom the breakage at this point is in effect interiorly positioned withrespect to the final tile and does not project to interfere with thefitting of the individual tiles.

As clearly shown in Figure 5, the present inlvention provides-aconstruction element which is 4 substantially prismatic in form, havingtop, end

'and side building surfaces. -The recess 62 exlongitudinally of the`opposite side surby/the reference numeral 6,4.

extending, irregular or broken surface designated which reside thesurfaces 58. Thus, when assembled in a Wall or lfloor structure, asshown in VFigure 6, the construction units may be accurately In'.accordancev with the preferred V'embodiment` alined, as shown in theiigure, and positioned as l closely as may be desired to produce amortar joint 66 of the desired dimensions. As shown in the iigure, themortar lls the longitudinally ex.

tending recesses 62 and contacts directly with the f irregular, brokensurface 64, insuring a substantially perfect degree of mortar'adhesioneven though the vadjacent units may be set relatively closelytogether. yThe present invention provides a simple and effective ceramicconstruction unit and process for producing the same which reducesproduction losses andcostsand results in a iinal product of improvedcharacter and quality. j lWhen proceeding in accordance with theipresentl invention, the ladverse effectsof the thermal conductivity ofthe 'material being; burned is overcome. Clay of the kilnin accordancewith one of the prior methods of practice mentioned above, thlstechnicalfactor is responsible forinordinately slow burning ofthe mass aresulting high fuel cost and a high percentage of cracked units as aresult of the socalled cooling cracks which occur when the kiln isycooled.

In accordance with the present invention it is 'contemplated' that vtheinstant flue-shaped extruded units be arranged in the kiln preferablysuperposed on end so that the gases and heat of y the kiln/will passfreely vertically through the mass to directly heat all parts uniformly.Stresses, such as are normally set up during burningand which tend towarp the elements, are

permitted to `act harmlessly by the bridging or connecting portions 42which, being located adjacent tl'ie side surfaces of the respectivetiles and being relatively thin, absorb all of the twisting strainswithout transmitting them to the adjacent units. In other words, therelatively thin portion adapted zto bebroken, after burning, in effectlacts as a pivot or hinge and permits relative twisting of the portionsto absorb the warpage inherent in .the burning operation.

, The rpresent invention, moreover, provides a highly desired,roughened, irregular inish on the surfaces toi be mortared which insuresproper mortar `adhesion: without the necessity of v a protrudingv orprojecting burnv It is to be noted lin this connection that the entiremortar receiving periphery o'fthe tile, including the end surfaces 60,has desirable mortar securing properties. The end surfaces 60, beingformed by cutting the continuous clay bar, are roughened sufciently toprovide slightly ragged faces for the purpose of enhancing this effect.l

While the present invention^has been described as being carried out withthe assistance of an extruding machine, it will be understood that vari-Cil ous other forming machines may be employed. The lextruded sectionforming the vpreferred embodiment of the present disclosure comprises ingeneral four tile unit sections polygonally arranged in a quadrangle andjoined by corner members, but it will be understood that various' otherspecific configurations will come within the scope and intent of thepresent invention, particularly' those wherein the tile sections aregenerally polygonally positioned in the integral element.

, InV accordance with the present invention the corner portions of theextruded unit designated by the numeral 40 are, after burning andseparating from the tile units, employed in the construction ofdecorative floor tile assemblies, particularly wherein impermeability islnot an im portant factor. It has l been found that the taperedprotruding extensions 42, which form the bridging portion in theoriginal unit, may be employed to accurately space these units, bothfrom adjacent units and from the supporting floor. In

other words, Vthe corner elements 40, as shown in Figure 4, are employedin oors, for example, Where it is desired that the mortar joints be ofuniform width while at the same time being relatively wide.

Changes may be made in the form, construction and arrangement of theseveral parts without departing from the spirit or scope of theinvenlion, or sacrificing any of its attendant advantages, the formherein described being a preferred .embodiment for the purpose ofillustrating the llongitudinally extending, irregular, broken surfaceoccupying a portion of the interior surface of said recesses and adaptedto promote mortar adhesion but having substantially all projectingportions thereof positioned below the outer plane of said side surfaces.

2. A ceramic building unit of generally prismatic form having oppositeside surfaces, said side surfaces being recessed, said recessesinteriorly thereof comprising irregular, jagged surfaces formed bybreaking a member integrally joining With a portion of said recesses.

3. A ceramic building unitpf generally prismatic form having oppositeside walls, said side walls being provided with longitudinally extendingside recesses formed therein, said recesses at a point spaced interiorlyof the plane of said side walls comprising .,irregular, jagged surfacesformed by breaking integral portions therefrom and adapted to promotemortar adhesion without providing projecting portions.

4. A building unit having a plurality of surfaces adapted to bejuxtaposed to similar surfaces in adjacent building units to form bondedjoints, said" surfaces being recessed, irregular, jagged surfaces formedinteriorly of said recesses and being so arranged that said irregular'portions do not extend substantially out of the recesses whereby toprovide improvedmortar adhering surfaces without `requiring substantialthickness of mortar joint.

5, A ceramic be assembled with vother similar units to provide afinished wall or floor structure, said unit hav.

wall or floor structure, and having at least onev side portion adaptedto receive mortar, said side portion comprising a recess extendinginwardly of said side and comprising an irregular broken mortar recevingsurface within said recess adapted to receive mortar to provide apermanently cemented nal assembly.

'7, Al ceramic building unit adapted to beassembled with other units tovprovide ay finished wall yor oor structure, and having at least oneside portion adapted to receive mortar, said side portion comprising arecess formed in said side and comprising an irregular broken mortarreceiving surface within said recess adapted to receive mortar toprovide a permanently cemented nal assembly, said recess extending'longitudinally of said side surface and being spaced from the lateralmarginal edges of said side surface.

8. A ceramic building unit adapted to be assembled with other units toprovide a finished wall or floor structure, and having at least one sideportion adapted to receive mortar, saidside portion comprising a recessformed in said Side and comprising an irregular broken mortar 're--yceiving surface within said recess adapted to receive mortar to providea permanently cemented final assembly, said recess ext-endinglongitudinal- 'ly of said side surface and being spaced from the lateralmarginal portions thereof, said ir- -regular broken surface portionbeing formed longitudinally of said recess andoccupying a.

portion thereof only, the remainder of said re" cess being defined byregular, even surface portions.`

" 9; A ceramic building unit adapted to be assembled with otherunits toprovide a finished wall or floor structure, andhaving at least one sideportion adapted to receive mortar, said side portion comprising a recessformed in said side and comprising an irregular broken mortar receivingsurface within said recess adaptedto receive mortar to provide apermanently cemented final assembly, said recess extendingVlongitudinally of said side surface and being spaced from the lateralmarginal portions thereof, said Y irregular jagged surface portionsextending longitudinally and centrally of said recess and havingsubstantially all the jagged portions thereof positioned interiorly ofthe planeof said lateral marginal portions.

10. A fired Vtile member having longitudinally extending, opposed,parallel Vside surfaces provided With longitudinally extending, recessesdisposed centrally of said side surfaces, a portion of. each recessbeing defined by a jagged mortar receiving surface spaced from bothlateral side margins of said recess and located substantially interiorlyof the planes of said'side walls.

GORDON W. REED.

building unit adapted to

